Stationary and mobile test rig applications
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n For asynchronous and synchronous drives
n For a variety of high performance test applications such as trains,
transformers and special motors
n Individually customized with scalable, modular performance levels
n Low-level electromagnetic emissions for sensitive test rig applications
n User-friendly service software and interface design
n Unmatched infrastructure including full laboratory to pretest multiple test
systems prior to commissioning
n Over 600 systems in operation worldwide
References: AVL LIST, Deutsche Bahn, HIGHVOLT
POWER CONVERTER AT A GLANCE
PowerTech is THE specialist in high performance converter technology for high performance test rigs. With over 600 installations worldwide, PowerTech offers unmatched product performance, know how, service experience and testing infrastructure. PowerTech converters for test rig applications are used for:
n Product development and end of line testingn Combustion motors, gears and hybrid drive trainsn High voltage transformer testingn Rail testing of pantographs, propulsion and braking n Electric motor and generator testingn Component testing of diverse industriesn Testing of industrial machines, compressors and
special motors
HIGHLY DYNAMIC TEST BENCHES FORM THE BACKBONE OF INDUSTRIAL DEVELOPMENT: To ensure that systems work reliably and meet performance requirements
PowerTech converters enable the turnkey simulation of technological processes. This contributes to lower product development costs and faster development cycles. The use of intelligent power modules, compact design, minimal number of components and forced air and water cooling define PowerTech’s state of the art technology. This is why almost all Formula 1 racing teams now use the PowerTech family for their development.
TECHNICAL FEATURESn IGBT-based four-quadrant technologyn With voltage link and pulsed mains convertern AFE - active front end functionalityn Active harmonic compensation for best possible grid qualityn Reactive power management with adjustable cos phin Maximum output frequency of up to 2 500 Hzn Maximum IGBT pulse frequency of up to 15 kHzn Excellent field-oriented control propertiesn Low losses and high immunity to electromagnetic interferencen Minimal electromagnetic emissionsn Single-phase/multi-phase solutionsn Modular, flexible design and constructionn Optimised air or water-coolingn Support of common field bus systems and binary interfacesn User-friendly service software and interface design
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1 Control electronics2 Power module with air cooling, water cooling as an option
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Knorr-Bremse Powertech GmbH
Am Borsigturm 10013507 Berlin, GermanyTel.: +49 30 297725 [email protected]
Knorr-Bremse Powertech GmbH & Co. KG
Ohmstraße 183607 Holzkirchen, GermanyTel.: +49 8024 990 [email protected]
Knorr-Bremse Powertech Corp. USA
300 International Drive, Suite 2Mount Olive, New Jersey 07828, USATel.: +1 973 527 [email protected]
Knorr-Bremse Powertech China
Building 4, Jingxi Industry Park2 Jingui Road, Hudai Town, Binhu District214161 Wuxi, Jiangsu Province, PR ChinaTel.: +86 510 6888 [email protected]
[email protected] W W . K B - P O W E R T E C H . C O MW W W . K N O R R - B R E M S E . C O M
This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark „K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2016 © Knorr-Bremse AG. All rights reserved. Including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.
TESTING FEATURES
Load tests with air- and liquid-cooled equipment and machinery n Test beds for in-house coupling of motor/converter
drive setsn Testing capabilities for determining vibration, velocities,
torques and speedsn Motors can be run with dynamic as well as stationary tests
e.g. for thermal testsn Workshop is capable of adapting customized
shaft connections
In-house facilities for testing of grid faults Realization of simulated grids for product tests n Adjustable grid voltage 0 - 830 V n Adjustable grid frequency 0 - 200 Hzn 700 A continuous reactive current possiblen 2000 A peak current for LVRT tests possiblen Simulation of flicker effects, LVRT, HVRT, harmonics
FACILITY FEATURES
Feed-in possibilities n Terminal areas with 400 V and a capacity of 1.3 MVA n Terminal areas with 690 V and a capacity of 2.0 MVA n Variable source 0 - 200 Hz, 0 - 690V
DC voltage source n 0 - 1000 V DC 350A recovery-capable
Loading devices n Dynamometer with 300 kW, 0 - 7 000 U/minn Transformer / inductor combination for loop operation
up to 2.0 MVA
Internal test rigsn Air-suspended prestressed bed for motor testingn Unsuspended prestressed bed for motor testing
Cooling equipmentn Water / water heat exchanger n Additional equipment according to customer requirement
EXTENSIVE TESTING FACILITIES IN-HOUSE
PowerTech has years of experience in testing with high power applications. Before delivery to the customer, each converter is tested with the original motor – only a fully tested package of power converter and motor is delivered to our customer. New motor types are “identified” with special load tests. That ensures a high accurate control of the torques – and in the end, best quality.
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APPLICATION EXAMPLES
STATIONARY HIGH-VOLTAGE TRANSFORMER TEST FACILITY
Train component testing (e.g. train transformers, propulsion inverters and motors) used in different voltage levels.
Solutionn Modular designed frequency converter with DC bus and active front end n Motor inverter as load for the unit under testn Supply of the auxiliary voltages n Control cabinet for the internal power supply and protectionn Advanced control functions, including safety circuit for safe stop n Different I/O’s, including interface for different field bus versions (Profibus,
Profinet, CAN)
TEST RIGS FOR RAILWAY INDUSTRY
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S Antriebsstrang-belastung
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PowerTech converters are used as a voltage supply for test facilities that test transformers according to IEC. These facilities are used for insulation tests and endurance tests.
Solutionn Very high output power and parallel converter operation are possiblen High level of EMC experience is required as test routines with partial
discharge measurements during converter operation occurn Short-circuit-proof, three-phase or single-phase operation, harmonics
stabilization of THD and DC offsetn Also suitable for mobile high-voltage transformer testing facilities
TEST RIGS FOR MOTORS, GEARS AND HYBRID DRIVE TRAINS
E Engine
P Primemover
W Wheels
T Transmission output
D Drive
PowerTech converters are deployed in test rigs for motors, gears and hybrid drive trains. Any configuration is possible: from a compact, reliable test bench for combustion engines to a test rig with maximum dynamics.
Solutionn Control of asynchronous and synchronous motors with up to 24 000 rpmn High dynamic speed and torque control with a step response of < 1 msn Frequency limit of the drive system at 2500 Hz with an IGBT pulse
frequency of up to 15 kHz with large test systemsn Speed change gradient of the drive system: 100 000 rpm/sn For Formula One applications with up to 1000 000 rpm/sn Battery simulation of 50 kW to 1 000 kW
The system of electric motor and PowerTech converter replace each of the mentioned components for simulating technological processes:
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TP
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D
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Load of propulsion
External AC/DC auxiliary power supply
Simulation of AC- or DC catenary voltage
1100 V DC
Sine wave filter
Step up trafo
0 - 170 kV5 MVA
Static frequency converter
690 V AC2.5 MW
Transformer under test
WORLD LEADER FOR HIGH DYNAMIC POWER CONVERTERS IN THE AUTOMOTIVE TESTING AREA
About 600 power converters delivered worldwide for n Motor test benches for testing combustion engines,
universal drives, electric drivesn Gear test benches as the most complex in the automotive
testing industryn Combustion shock simulation with power converter
and electric motorn Motorsport applications for highest dynamics, as required
by Formula 1, IndyCarn Hybrid drive test benches, AC and DC converters provide
variable energy source, for e.g. battery simulationn High voltage transformers test rigs, e.g. insulation tests,
lifetime testsn Train component test rigs for testing of train transformers,
propulsion inverters and motors
QUALIFIED SYSTEM PARTNER
System solutions for converters and motorsn PowerTech closely works together with well-known,
qualified motor suppliers like VEM, Schorch, Krebs und Aulich, LDW, Faurndau
n Coordinated solutions in electrical parameters, interpretation of the encoders and protection functions
n Preconfigured, proven and therefore reliable compilations of components of the electric drive train
333 3 AC 3* 3*
3 AC
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This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark „K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2016 © Knorr-Bremse AG. All rights reserved. Including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.
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TECHNICAL DATAConverters for test rig applications
Line voltage
Rated voltage 380 - 480 V, 380 - 690 V
Grid frequency 50 / 60 Hz
AC output
Nominal power 50 - 6 000 kW, expandable to 12 MW with parallel connection
Maximum frequency 2 500 Hz
Rated voltage 0 - 500 V AC, 0 - 700 V AC3 phase or single phase
DC output
Rated voltage 0 - 800 V DC, 0 - 1 200 V DC
Nominal power up to 4 MW expandable through parallel connections
ELECTRICS MECHANICS
Fieldbus systems CAN, Profibus, Ethercat
Housing Standard industrial cabinets
Cooling Air or water cooling
Protection IP23, IP54
Temperature range 0 to +45 °C
BLOCK DIAGRAM
Synchronous or asynchronous motors
Motor 1
Motor 2
Motor nLine-side converter
Line
Line filter
Circuit breaker
*Single-phase or DC/DC solutions also available
2. Motor-side converter
n Motor-side converter
1. Motor-side converter
I/O statusFieldbus
Converter control
Output inductor
DC link
PowerTech Converter GmbH
Am Borsigturm 10013507 BerlinGermanyPhone: +49 30 297725-0Fax: +49 30 297725-102
S A L E S @ K B - P O W E R T E C H . C O MW W W . K B - P O W E R T E C H . C O M Copyright 2020 © PowerTech Converter GmbH